Fujitsu AOTG18LACC Installation guide

Brand: Fujitsu

Model: AOTG18LACC

Category: Split-system air conditioners

Type: Installation guide

SPLIT AIR CONDITIONER

INSTALLATION MANUAL

(PART No. 9332809046-02)

R410A

REFRIGERANT

This Air Conditioner contains and operates

with refrigerant R410A.

THIS PRODUCT MUST ONLY BE INSTALLED OR SERVICED

BY QUALIFIED PERSONNEL.

Refer to Commonwealth, State, Territory and local legislation,

regulations, codes, installation & operation manuals, before

the installation, maintenance and/or service of this product.

This air conditioner uses new refrigerant HFC (R410A).

The basic installation work procedures are the same as conventional refrigerant (R22) models.

However, pay careful attention to the following points:

(1) Since the working pressure is 1.6 times higher than that of conventional refrigerant (R22) models, some of the piping and installation

and service tools are special. (See the table below.)

Especially, when replacing a conventional refrigerant (R22) model with a new refrigerant R410A model, always replace the conventional

piping and ﬂ are nuts with the R410A piping and ﬂ are nuts.

(2) Models that use refrigerant R410A have a different charging port thread diameter to prevent erroneous charging with conventional re-

frigerant (R22) and for safety. Therefore, check beforehand. [The charging port thread diameter for R410A is 1/2 threads per inch.]

(3) Be more careful that foreign matter (oil, water, etc.) does not enter the piping than with refrigerant (R22) models. Also, when storing the

piping, securely seal the opening by pinching, taping, etc.

(4) When charging the refrigerant, take into account the slight change in the composition of the gas and liquid phases, and always charge

from the liquid phase side whose composition is stable.

Special tools for R410A

Tool name Contents of change

Gauge manifold

Pressure is high and cannot be measured with a conventional gauge. To prevent erroneous mixing of other refrigerants, the

diameter of each port has been changed.

It is recommended the gauge with seals-0.1 to 5.3 MPa (-1 to 53 bar) for high pressure.

-0.1 to 3.8 MPa (-1 to 38 bar) for low pressure.

Charge hose

To increase pressure resistance, the hose material and base size were changed.

Vacuum pump

A conventional vacuum pump can be used by installing a vacuum pump adapter.

Gas leakage detector

Special gas leakage detector for HFC refrigerant R410A.

Copper pipes

It is necessary to use seamless copper pipes and it is desirable that the amount of residual

oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or

discolored portion (especially on the interior surface). Otherwise, the expansion value or

capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pressure higher than when using R22, it is

necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Table.

Never use copper pipes thinner than that in the table even when it is available on the market.

Thicknesses of Annealed Copper Pipes

Thickness (mm)

Nominal

diameter (in.)

Outer diameter

(mm)

R410A [ref.] R22

1/4 6.35 0.80 0.80

1/2 12.70 0.80 0.80

WARNING

Do not use the existing (for R22) piping and ﬂ are nuts.

• If the existing materials are used, the pressure inside the refrigerant cycle will rise and cause breakage, injury, etc. (Use the special R410A materials.)

When installing and relocating the air conditioner, do not mix gases other than the speciﬁ ed refrigerant (R410A) to enter the refrigerant cycle.

• If air or other gas enters the refrigerant cycle, the pressure inside the cycle will rise to an abnormally high value and cause breakage, injury, etc.

For authorized service personnel only.

WARNING

For the room air conditioner to operate satisfactory, install it as outlined in this installation manual.

Connect the indoor unit and outdoor unit with the air conditioner piping and cables available standards parts. This installation manual describes the correct

connections using the standard accessories and the parts speciﬁ ed in this installation manual.

Have installation work done by authorized service personnel only.

Do not use this equipment with air or any other unspeciﬁ ed refrigerant in the refrigerant lines. Excess pressure can cause a rupture.

Do not use an extension cable.

Do not turn on the power until all installation work is complete.

• Be careful not to scratch the air conditioner when handling it.

• After installation, explain correct operation to the customer, using the operating manual.

• Let the customer keep this installation manual because it is used when the air conditioner is serviced or moved.

• The maximum length of the piping is 30 m. The minimum length of the piping is 5 m. The maximum height difference of the piping is 20 m.

• If the units are further apart than these, correct operation can not be guaranteed.

Tapping screw

Hooks

Connector cover

Tapping screw

OUTDOOR UNIT INSTALLATION

OPERATING

RANGE

WARNING

Install the unit where it will not be tilted by more than 5°.

When installing the outdoor unit where it may exposed to strong wind, fasten it securely.

Outdoor temperature

Cooling Mode

Dry Mode

About -10 to 46°C

Heating Mode About -15 to 24°C

POWER

WARNING

The rated voltage of this product is 240 V AC 50 Hz. Use a circuit breaker and receptacle matched to the capacity of the air

conditioner.

Do not extend the power cable.

Before turning on the power, check if the voltage is within the

220 V -10 % to 240 V +10 % range.

Perform wiring work in accordance with standards so that the air conditioner

can be operated safely and positively.

Always use a special branch circuit and install a special receptacle to

supply power to the room air conditioner.

Install a leakage circuit breaker in accordance with the related laws and

regulations and electric company standards.

CAUTION

The power source capacity must be the sum of the air conditioner current and the current of other electrical appliances. When the current contracted ca-

pacity is insufﬁ cient, change the contracted capacity.

When the voltage is low and the air conditioner is difﬁ cult to start, contact the power company the voltage raised.

ELECTRICAL REQUIREMENT

• Install all electrical works in accordance to the

national standard.

• Install the disconnect device with a contact

gap of at least 3 mm in all poles nearby the

units. (Both indoor unit and outdoor unit)

• Install the circuit breaker nearby the units.

• Electric wire size and breaker capacity:

Cable Conductor size [mm

] Type Remarks

Power supply cable 4.0

Type 60245

IEC 57

2Cable+Earth(Ground),1φ240V

Connection cable 1.5 3Cable+Earth(Ground),1φ240V

Installation instruction on the back.

Decide the mounting position with the customer as follows:

(1) If possible, do not install the unit where it will be exposed to direct sunlight. (If necessary, install a blind that

does not interfere with the air ﬂ ow.)

(2) Do not install the unit where a strong wind blows or where it is very dusty.

(3) Do not install the unit where people pass.

(4) Take your neighbors into consideration so that they are not disturbed by air blowing into their windows or by

noise.

(5) Provide the space shown in the ﬁ gure so that the air ﬂ ow is not blocked. Also for efﬁ cient operation, leave

open three of the four directions front, rear, and both sides.

WARNING

Install at a place that can withstand the weight of the outdoor units and install positively so that the units will

not topple or fall.

CAUTION

Do not install the outdoor unit in the following areas:

• Area with high salt content, such as at the seaside. It will deteriorate metal parts, causing the parts to fail or

the unit to leak water.

• Area ﬁ lled with mineral oil or containing a large amount of splashed oil or steam. It will deteriorate plastic

parts, causing the parts to fail or the unit to leak water.

• Area that generates substances that adversely affect the equipment, such as sulfuric gas, chlorine gas,

acid, or alkali. It will cause the copper pipes and brazed joints to corrode, which can cause refrigerant leakage.

• Area containing equipment that generates electromagnetic interference. It will cause the control system to

malfunction, preventing the unit from operating normally.

• Area that can cause combustible gas to leak, contains suspended carbon ﬁ bers or ﬂ ammable dust, or volatile

inﬂ ammables such as paint thinner or gasoline. If gas leaks and settles around the unit, it can cause a ﬁ re.

• Area that has heat sources, vapors, or the risk of the leakage of ﬂ ammable gas in the vicinity.

• Area where small animals may live. It may cause failure, smoke or ﬁ re if small animals enter and touch

internal electrical parts.

• Area where animals may urinate on the unit or ammonia may be generated.

When the outdoor temperature is 0°C or less, do not use the accessory drain pipe . If the drain pipe are

used, the drain water in the pipe may freeze in extremely cold weather.

Do not place any other electrical products or household belongings under indoor unit or outdoor unit. Dripping

condensation from the unit might get them wet, and may cause damage or malfunction of your property.

If children under 10 years old may approach the unit, take preventive measures so that they cannot reach

the unit.

Do not touch the aluminum ﬁ ns of heat exchanger built-in the indoor or outdoor unit to avoid personal injury

when you install or maintain the unit.

In the area with heavy snowfall, if the intake and outlet of outdoor units blocked with snow, it might become

difﬁ cult to get warm and it is likely to cause of the breakdown.

Please construct a canopy and a ped-estal or place the unit on a high stand (local conﬁ gured).

SELECTING THE MOUNTING POSITION

54 cm

32 cm

INSTALLATION

DIAGRAM

INDOOR UNIT

[OUTDOOR UNIT]

10 cm

or over

60 cm or over

10 cm or over

20 cm

or over

25 cm

or over

5 cm or over

OUTDOOR UNIT ACCESSORIES

Drain pipe

Drain cap

● Set the unit on a strong stand such as thing made of concrete blocks to

minimize shock and vibration.

● Do not set the unit directly on the ground because it will cause trouble.

Connector cover removal

• Remove the tapping screws.

Installing the connector cover

(1) After inserting the four hooks, then slide the cover.

(2) Tighten the tapping screws.

Outdoor

unit

bottom

Drain

pipe

Drain cap

Breaker

capacity

25(A)

NL321

12 3

Outdoor unit terminal block

Indoor unit terminal block

Connection cable

Earth

screw

Earth

screw

Power supply cable

(1) Remove the outdoor unit connector cover.

(2) Bend the end of the cable as shown in the ﬁ gure.

(3) Connect the end of the connection cable fully into the

terminal block.

(4) Fasten the sheath with a cable clamp.

(5) Install the connector cover.

Connection cable wiring

Run the connection cable to the rear of the outdoor unit

within the

range of the arrows shown in the ﬁ gure.

(The connector cover becomes difﬁ cult to install.)

30mm

12mm

5mm

12mm

20mm

12mm

5mm

12mm

20mm

Connection cable Power supply cable

OUTDOOR UNIT WIRING

Connection cable

Cable clamp

Earth

screw

Insulation

tube

Connection cable

Hole

8 cm

10 cm

CAUTION

Match the terminal block numbers and connection cable colors with those

of the indoor unit.

Erroneous wiring may cause burning of the electric parts.

Always fasten the outside covering of the connection cable with the cable

clamp. (If the insulator is chafed, electric leakage may occur.)

Securely earth the power cable.

Connect the connection cables ﬁ rmly to the terminal block. Imperfect installa-

tion may cause a ﬁ re.

Do not use the earth screw for an external connector. Only use for intercon-

nection between two units.

To avoid discharging refrigerant into the atmosphere at the time of relocation or disposal, recover refrigerant by doing the cooling operation or forced cooling

operation according to the following procedure. (When the cooling operation cannot start in winter, and so on, start the forced cooling operation.)

(1) Do the air purging of the charge hose by connecting the charging hose of gauge manifold to the charging port of 3 way valve (large) and opening the low-

pressure valve slightly.

(2) Close the valve stem of 2 way valve (small) completely.

(3) Start the cooling operation or following forced cooling operation.

When using the remote controller

Press the TEST RUN button after starting the cooling operation by the remote controller.

The operation indicator lamp and timer indicator lamp will begin to ﬂ ash simultaneously during test run.

When using the MANUAL AUTO button of the indoor unit (The remote controller is lost, and so on.)

Keep on pressing the MANUAL AUTO button of the indoor unit for more than 10 seconds.

(The forced cooling operation cannot start if the MANUAL AUTO button is not kept on pressing for more than 10 seconds.)

(4) Close the valve stem of 3 way valve (large) when the reading on the compound pressure gage becomes 0.05~0 MPa (0.5~0 kg/cm

(5) Stop the operation.

• Press the START/STOP button of the remote controller to stop the operation.

• Press the MANUAL AUTO button when stopping the operation from indoor unit side.

(It is not necessary to press on keeping for more than 10 seconds.)

WARNING

During the pump-down operation, make sure that the compressor is turned off before you remove the refrigerant piping.

Do not remove the connection pipe while the compressor is in operation 2 way or 3 way valve open. This may cause abnormal pressure in the refrigera-

tion cycle that leads to rupture and even injury.

PUMP DOWN

CONNECTION

(1) Install the outdoor unit wall cap (supplied with the optional installation

set or procured at the site) to the wall pipe.

(2) Connect the outdoor unit and indoor unit piping.

(3) After matching the center of the ﬂ are surface and tightening the nut

hand tight, tighten the nut to the speciﬁ ed tightening torque with a torque

wrench. (Table 1)

FLARING

(1) Cut the connection pipe to the necessary

length with a pipe cutter.

(2) Hold the pipe downward so that cuttings

will not enter the pipe and remove the

burrs.

(3) Insert the ﬂ are nut onto the pipe and ﬂ are

the pipe with a ﬂ aring tool.

Insert the ﬂ are nut (always use the ﬂ are nut attached to the indoor and out-

door units respectively) onto the pipe and perform the ﬂ are processing with

a ﬂ are tool.

Use the special R410A ﬂ are tool, or the conventional (for R22) ﬂ are tool.

When using the conventional ﬂ are tool, always use an allowance adjustment gauge and

secure the A dimension shown in table 2 .

BENDING PIPES

(1) When bending the pipe, be careful not to crush it.

(2) To prevent breaking of the pipe, avoid sharp bends.

Bend the pipe with a radius of curvature of 150 mm or over.

(3) If the copper pipe is bend the pipe or pulled to often, it will become stiff.

Do not bend the pipes more than three times at one place.

CONNECTING THE PIPING

Tighten with two wrenches.

Torque

wrench

Wrench (ﬁ xed)

Flare nut

Indoor unit pipe

Connection pipe

To prevent gas leakage, coat the ﬂ are

surface with refrigerator oil.

Table 1 : Flare nut size and tightening torque

Flare nut

Diameter (mm) Torque (N

6.35 mm dia. 17 16 18

12.70 mm dia. 26 49 61

Table 2 : Pipe outside diameter

Pipe outside

diameter

A (mm)

Flare tool for

R410A, clutch type

Conventional (R22) ﬂ are tool

Clutch type Wing nut type

ø 6.35 mm (1/4”) 0 to 0.5 1.0 to 1.5 1.5 to 2.0

ø 12.70 mm (1/2”) 0 to 0.5 1.0 to 1.5 1.5 to 2.0

WARNING

During installation, make sure that the refrigerant pipe is attached ﬁ rmly

before you run the compressor. Do not operate the compressor under the

condition of refrigerant piping not attached properly with 2-way or 3-way

valve open. This may cause abnormal pressure in the refrigeration cycle

that leads to rupture and even injury.

Check if [L] is ﬂ ared uniformly and is

not cracked or scratched.

Die

Pipe

AIR PURGE

Always use a vacuum pump to purge the air.

Refrigerant for purging the air is not charged in the outdoor unit at the

factory.

Close the high pressure side valve of the gauge manifold fully and do not

operate it during the following work.

1. Check if the piping connections are secure.

2. Check that the stems of 2-way valve and 3-way valve are closed fully.

3. Connect the gauge manifold charge hose to the charging port of the 3-way

valve (side with the projection for pushing in the valve core).

4. Open the low pressure side valve of the gauge manifold fully.

5. Operate the vacuum pump and start pump down.

6. Slowly loosen the ﬂ are nut of the 3-way valve and check if air enters, then

retighten the ﬂ are nut.

(When the ﬂ are nut is loosened the operating sound of the vacuum pump

changes and the reading of the compound pressure gauge goes from minus

to zero.)

7. Pump down the system for at least 15 minutes, then check if the compound

pressure gauge reads -0.1 MPa (-76 cmHg, -1 bar).

8. At the end of pump down, close the low pressure side gauge of the gauge

manifold fully and stop the vacuum pump.

9. Slowly loosen the valve stem of the 3-way valve. When the compound

pressure gauge reading reaches 0.1-0.2 MPa, retighten the valve stem and

disconnect the charge hose from the 3-way valve charging port.

(If the stem of the 3-way valve is opened fully before the charge hose is dis-

connected, it may be difﬁ cult to disconnect the charge hose.)

10. Fully open the valve stems of the 2-way valve and 3-way valve using a hexagon

wrench. (After the valve stem begins to turn, turn it with a torque of less than 2.9

N • m (30 kgf • cm) until it stops turning.)

11. Firmly tighten the 2-way valve and 3-way valve blank cap and the charging

port cap.

Additional charge

Refrigerant suitable for a piping length of 15 m is charged in the outdoor unit

at the factory.

When the piping is longer than 15 m, additional charging is necessary.

For the additional amount, see the table below.

Pipe length 15 m 20 m 25m 30 m Rate

Additional refrigerant None +100g +200g +300 g 20 g/m

3-way valve

2-way valve

Flare nut

Valve stem

Blank cap

Charge hose

Charging port

Vacuum pump

Charge

hose

High

pressure

side valve

(closed)

Pressure gauge

Gauge manifold

Compound pressure gauge

-0.1 MPa

(-76 cmHg

-1 bar)

Low pressure

side valve

Charging port cap

CAUTION

Refrigerant must not be discharged into atmosphere.

After connecting the piping, check the joints for gas leakage with gas

leak detector.

Tightening torque

Blank cap(2-way valve) 20 to 25 N•m (200 to 250 kgf•cm)

Blank cap(3-way valve) 28 to 32 N•m (280 to 320 kgf•cm)

Charging port cap 12.5 to 16 N•m (125 to 160 kgf•cm)

CAUTION

When adding refrigerant, add the refrigerant from the charging port at

the completion of work.

The maximum length of the piping is 30 m. If the units are

further apart than this, correct operation can not be guaranteed.

Between 15 m and 30 m, when using a connection pipe other than that in

the table, charge additional refrigerant with 20 g/1 m as the criteria.

• Perform test operation and check items below.

• For the test operation method, refer to the operating manual.

• The outdoor unit, may not operate, depending on the room temperature. In this case, press the TEST RUN button on the remote controller while the air

conditioner is running, (Point the transmitter section of the remote controller toward the air conditioner and press the TEST RUN button with the tip of a ball-

point pen, etc.)

• To end test operation, press the remote controller START/STOP button.

(When the air conditioner is run by pressing the TEST RUN button, the OPERATION indicator lamp and TIMER indica-

tor lamp of the indoor unit will simultaneously ﬂ ash slowly.)

OUTDOOR UNIT

(1) Is there any abnormal noise and vibration during operation?

(2) Will noise, wind, or drain water from the unit disturb the neighbors?

(3) Is there any gas leakage?

TEST RUN

Transmitter section

Test run button

CAUTION